Fabrication Process for Garments and Other Fabric Products

ABSTRACT

Fabrication processes are provided for a fabric product that provide a continuous moisture and/or thermal barrier around the fabric product, eliminating moisture and thermal leakage through seams and other stitching perforations, and creating an equal barrier quality throughout the structure of the fabric product. A fabric product is also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 15/111,026, filed Jul. 12, 2016, which is a U.S. National Phase ofPCT/US2014/046142, filed Jul. 10, 2014, which claims the benefit under35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/927,677,filed Jan. 15, 2014, entitled Fabrication of Waterproof Garments ByIn-Line Lamination Process, the disclosures of which are incorporated byreference herein in their entireties.

BACKGROUND

The availability of waterproof or water resistant fabrics for outerwearpresents challenges to create seams that share the water sheddingcharacteristics of the fabrics. Waterproof or water resistant garmentsare constructed using laminated waterproof fabrics, in which an outerface fabric of water repellant material and a hydrostatic barriermaterial inside the outer face fabric have been bonded together prior tofabrication of the garment.

The use of such laminated fabrics containing a hydrostatic barriermaterial poses the problem of how to join the barrier material across aseam without introducing leak pathways. Additionally, the seams providea weak point in the garment, such that, even if the hydrostatic barriermaterial is capable of withstanding tens or hundreds of washings withoutdegradation, the seams generally do not withstand more than five or sowashings. Thus, the seams are a prime location for the garment to beginto degrade.

An insulating layer may also be present in a garment, and seams formleakage pathways for heat in thermally insulated garments. Perforationsfrom quilt stitching can also provide pathways for heat loss in garmentsthat include quilted components.

SUMMARY OF THE INVENTION

The present invention relates to a fabrication process for a fabricproduct that provides a continuous moisture and/or thermal barrieraround the fabric product, eliminating leakage through seams and otherstitching perforations. The process provides a fabric product having anequal barrier quality throughout the structure of the fabric product.Resistance to hydrostatic pressure, heat loss, and penetration byliquids, gases and agents such as blood borne pathogens, viruses andbacteria can be equalized across the entire barrier, including acrossthe barrier seams, of the fabric product.

In one aspect, a process for fabricating a multi-layered fabric productcomprises:

(a) providing fabric pattern panels of at least an outer shell fabric, abarrier layer and an adhesive interposed between the outer shell fabricand the barrier layer, the outer shell fabric and the barrier layerprovided as separate fabric pattern panels, the barrier layer comprisingone of a moisture barrier and an insulation barrier;

(b) aligning each barrier layer fabric pattern panel to a correspondingone or more outer shell fabric pattern panels to form a plurality ofcomposite fabric pattern panels;

(c) fusing each of the composite fabric pattern panels together, leavingan area about a perimeter of each composite fabric pattern panelunfused;

(d) seaming the outer shell fabric pattern panels together along thearea left unfused;

(e) folding one or more of the unfused areas of the barrier layer andthe adhesive back so that the unfused areas of the barrier layer and theadhesive overlap;

(f) fusing a plurality of the composite fabric pattern panels togetherto form a complete fabric product having a continuous barrier extendingacross an inner surface of the outer shell fabric and at least one seambetween the outer shell fabric pattern panels.

The invention also provides a multi-layered fabric product comprising anouter shell fabric comprising a plurality of fabric pattern panels, atleast one seam formed along edges of fabric pattern panels to join thefabric pattern panels together, the outer shell fabric having an innerside and an outer side; and a barrier layer comprising a plurality offabric pattern panels fused to the inner side of the outer shell fabric,the fabric pattern panels overlapping in an area extending along theseam of the outer shell fabric, wherein a continuous barrier extendsacross the inner surface of the outer shell fabric and the at least oneseam between the outer shell fabric pattern panels.

In other aspects, the barrier layer comprises a membrane barrier film.The membrane barrier film can comprise a hydrophobic polymer membrane ora hydrostatic barrier membrane. The membrane barrier film can comprise amicro porous structure that allows transport of water vapor across themembrane barrier film while preventing or minimizing transport of liquidwater across the membrane barrier film. The membrane barrier film caninclude activated carbon particles with microporous structures. Themembrane barrier film can comprise a microporouspolytetrafluoroethylene, a nanoporous polytetrafluoroethylene, anexpanded PTFE, a polyurethane, a cross-linked polyurethane, apolypropylene, or a polyester.

In other aspects, the barrier layer can be capable of withstanding ahydrostatic pressure of at least 1, 2, 3, 4, 5, 10, 15, 20, 25, 30, 35,40, 45, or 50 psi including across the at least one seam. The continuousbarrier can be equally resistant to hydrostatic pressure across theinner surface of the outer shell fabric and the at least one seam. Thecontinuous barrier can be equally resistant to at least one ofpathogenic microorganisms, blood borne pathogens, viruses, bacteria,liquid chemical agents, and gaseous chemical agents across the innersurface of the outer shell fabric and the at least one seam.

The barrier layer can comprise an insulation material. The insulationmaterial can comprise a natural or synthetic filament material.

The process can further include fusing an inner lining fabric patternpanel with a corresponding one of the plurality of composite fabricpattern panels and folding the inner lining fabric pattern panel backover the seam so that unfused areas overlap. The inner lining fabric cancomprise a fleece material or a tricot material. The inner lining fabriccan comprise multiple layers quilted together. The inner lining fabriccan comprise a polyester, a polyamide, a polyvinylchloride, apolyketone, a polysulfone, a polycarbonate, a fluoropolymer, apolyacrylate, a polyurethanes, a co-polyetherester, a polypropylene, anda co-polyetheramide.

In other aspects, the adhesive can comprise a powder adhesive, a webadhesive, a micro dot adhesive, a nano dot adhesive.

In other aspects, the outer shell fabric can comprises a polyester, apolyamide, a polyvinylchloride, a polyketone, a polysulfone, apolycarbonate, a fluoropolymer, a polyacrylate, a polyurethanes, aco-polyetherester, a polypropylene, and a co-polyetheramide. The outershell fabric can comprise multiple layers quilted together.

The process can further comprise sewing or ultrasonically welding theouter shell fabric pattern panels together along the area left unfused.

The process can include fusing the composite fabric pattern panelstogether on a three-dimensional pressing machine. The process of caninclude fusing the composite fabric pattern panels together on atwo-dimensional pressing machine. The process can include fusing each ofthe composite fabric pattern panels together with a soft set that allowsthe layers to be adjusted. The process can includes fusing each of thecomposite fabric pattern panels together with a hard set that does notallow the layers to be adjusted.

The product can comprise an article of clothing, a portion of an articleof clothing, a jacket, a coat, a parka, a raincoat, a cloak, a poncho, ashirt, a blouse, pants, shoes, boots, gloves, a hat, a hood, underwear,an undershirt, briefs, a bra, socks, a diaper, a protective suit forhandling of hazardous materials, a protective suit for a firefighter,military personnel, or medical personnel, a blanket, a towel, a sheet,pet bedding, a tent, a sleeping bag, a tarp, a boat cover, carpeting, arug, a mat, a window covering, and upholstery.

In another aspect, a process for fabricating a multi-layered fabricproduct comprises:

(a) providing fabric pattern panels of at least an outer shell fabric, abarrier layer and an adhesive interposed between the outer shell fabricand the barrier layer, the outer shell fabric and the barrier layerprovided as separate fabric pattern panels, the barrier layer comprisingone of a moisture barrier and an insulation barrier, the fabric patternpanel of the barrier layer having a configuration corresponding to atleast two fabric pattern panels of the outer shell fabric seamedtogether;

(b) seaming the at least two outer shell fabric pattern panels togetheralong a seam to from a flat outer shell assembly;

(c) aligning the barrier layer fabric pattern panel to the flat outershell assembly to extend across the seam to form a composite fabricpattern panel;

(d) fusing the composite fabric pattern panel together, leaving an areaabout a perimeter of the composite fabric pattern panel unfused;

(e) seaming the outer shell assembly to a further outer shell piece;

(f) fusing the fabric product to form a complete fabric product having acontinuous barrier extending across an inner surface of the outer shellfabric and at least one seam between the outer shell fabric patternpanels.

In another aspect, a process for fabricating a multi-layered fabricprocess incorporating a moisture barrier layer, comprises:

(a) providing a membrane barrier film comprising a first membrane filmhaving a first melting temperature laminated to a second membrane filmhaving a second melting temperature lower than the first meltingtemperature, each of the first membrane film and the second membranefilm comprising a micro porous structure that allows transport of watervapor across the film while preventing or minimizing transport of liquidwater across the film;

(b) providing fabric pattern panels of at least an outer shell fabric,the membrane barrier film, and in inner lining fabric, the outer shellfabric and the barrier layer provided as separate fabric pattern panels,the barrier layer comprising one of a moisture barrier and an insulationbarrier;

(c) aligning each membrane barrier film fabric pattern panel to acorrespond one or more outer shell fabric pattern panels to form aplurality of composite fabric pattern panels;

(d) fusing each of the composite fabric pattern panels together at atemperature greater than the second melting temperature and less thanthe first melting temperature, leaving an area about a perimeter of eachcomposite fabric pattern panel unfused;

(e) seaming the outer shell fabric pattern panels together along thearea left unfused;

(f) folding the membrane barrier film and the inner lining fabric backover the seam so that the unfused areas of the membrane barrier film andthe inner lining fabric overlap;

(g) fusing all of the composite fabric pattern panels together to form acomplete fabric product having a continuous barrier extending across aninner surface of the outer shell fabric and at least one seam betweenthe outer shell fabric pattern panels.

The invention also provides a composite material comprising a firstlayer comprising a high melt membrane film, a second layer disposed on afirst side of the first layer and comprised of a low melt membrane film,the low melt membrane film having a melting temperature lower than amelting temperature of the high melt membrane film. The compositematerial can further include a third layer disposed on a second side ofthe first layer and comprising a lower melt film formed from a polyestermaterial, a polyether material, a polypropylene material or apolyurethane material; the lower melt membrane film having a meltingtemperature lower than the melting temperature of the low melt membranefilm. The composite material can in some embodiments provide a membranebarrier film to provide a moisture barrier in a fabric product.

DESCRIPTION OF THE DRAWINGS

The invention will be more fully understood from the following detaileddescription taken in conjunction with the accompanying drawings inwhich:

FIG. 1 is a schematic illustration of a multi-layer fabric product ofthe present invention;

FIG. 2 is a schematic illustration of one embodiment of fabric patternpanels formed in the fabrication process of the present invention;

FIG. 3 is a schematic illustration of the fabric pattern panels of FIG.2 at a further step in the fabrication process;

FIG. 4 is a schematic illustration of the fabric pattern panels of FIG.3 at a further step in the fabrication process;

FIG. 5 is a schematic illustration of the fabric pattern panels of FIG.4 at a further step in the fabrication process;

FIG. 6 is a schematic illustration of a further embodiment of amulti-layer fabric product;

FIG. 7 is a schematic illustration of a further multi-layer fabricproduct;

FIG. 8 is a schematic illustration of a still further multi-layer fabricproduct;

FIG. 9 is a schematic illustration of a still further multi-layer fabricproduct;

FIG. 10 is a schematic cross-sectional illustration of a multi-layerfabric product;

FIG. 11 is a schematic cross-sectional illustration of a furthermulti-layer fabric product; and

FIG. 12 is a schematic illustration of a still further multi-layerfabric product.

DETAILED DESCRIPTION OF THE INVENTION

A fabrication process is provided that creates a continuous barrieracross a multi-layer fabric product that incorporates seams, such as agarment or a garment sub-assembly. The barrier can be a hydrostaticbarrier that prevents or minimizes the infiltration of moisture. Thebarrier can alternatively or additionally be a thermal barrier thatminimizes heat loss through the fabric product. While developedprimarily for garments, the process can be used for other fabricproducts that incorporate seams.

The fabrication process employs a fusion process to create a laminatedfabric composite in a fabric pattern panel (FPP) configuration in linewith the construction of the fabric product. As described more fullybelow, the FPPs of each fabric layer are positioned and fused together,leaving an area around the perimeter unfused, which allows the barrierlayer and any additional inner layers to be folded back to expose anouter shell. The outer shell FPPs are seamed together, for example, bysewing or ultrasonic welding, along the exposed edges to assemble theouter shell of the fabric product. The barrier layer is not compromisedduring the seaming of the outer shell, because the barrier layer isfolded out of the way. Next, the barrier layer and any other layers arefolded back over the outer shell such that the unfused edges overlap orinterleave. All of the layers of the fabric product are then fusedtogether to complete the lamination process and form the complete fabricproduct.

In one aspect, the process is used to fabricate a multi-layer fabricproduct including, as the barrier layer, a membrane barrier film thatallows moisture vapor to escape outwardly through micro pores in themembrane barrier film but prevents liquid water from penetratinginwardly. The process provides complete surface coverage of the membranebarrier film across an inner surface including the seams of an outershell fabric and an inner surface of an inner lining fabric. The seamsin the outer shell fabric are thereby completely covered by the membranebarrier film, eliminating the need for seam tape.

The fabric pattern panels are fabricated in a manner that allows seamsin an outer shell and an inner lining to be matched or offset, andallows the panel composite structures to be the same or different. Theprocess sets the adhesive film structures in place, creating a uniformlaminated membrane barrier film layer. The fusing presses provide acontinuous pressure and thermal heat set of the adhesives in an evenflow through the fabric pattern panel composites.

The process results in a fused laminate that is superior to currentcommercial multi-layered membrane barrier film laminated fabrics. Theprocess can eliminate the lead time of purchasing outer shell fabricspre-laminated with a membrane barrier film. It can eliminate the need toinventory multi-layered laminated membrane barrier film fabrics, as eachouter shell fabric, membrane barrier film, adhesive compound and innerlining fabrics can be inventoried individually. It can eliminate therequirement for various fabric protective coatings, such as a separateapplication of a durable water repellency (DWR) coating on the surfaceof the shell fabrics after the commercial lamination process.

In one aspect, the process is used to fabricate a multi-layer fabricproduct including, as the barrier layer, an insulation layer orinsulation package that provides a continuous thermal barrier across thefabric product and reduces heat loss through the seams of the outershell. The process provides complete surface coverage of the insulationpackage across the inner surface of the outer shell fabric surface andthe inner surface of the inner lining fabric. The insulated seamsminimize thermal heat loss through the seam surface structures. Thisprocess allows the seams of the outer shell panel and the inner linerpanel to be matched or offset. The fabric pattern panels are alsodesigned to allow the panel composite structures to be the same ordifferent.

The process allows for greater variation in choices of the outer shellfabrics, membrane barrier films, adhesive, insulation fibers, and innerlinings, because the various materials can be individually selected andincorporated directly into the fabrication process at the factory. Thatis, it is not necessary to pre-order a pre-laminated fabric composite,such as an outer shell and membrane barrier, which requires determiningan optimum quantity for the particular fabric product to be fabricatedas well as resulting in seams that provide leakage pathways. Also,pre-ordering laminated fabric composites typically entails a wait ofseveral weeks or even months for delivery.

The outer shell fabric(s) and inner lining fabric(s) can be selected fora specific style and color and in the quantity of yardage required forthe fabric product being produced. The outer shell fabric can be anyfabric, but preferably is mechanically strong, abrasion resistant, andmay also be water repellent. The outer shell fabric can be, for example,a soft woven fabric, or any fabric woven or knit from one or more yarnsof synthetic or natural material. Similarly, the inner lining fabricscan be, for example, a soft woven fabric, or any fabric woven or knitfrom one or more yarns of synthetic or natural material. Materials forthe outer shell fabric and inner lining fabric can include, for example,polyesters, polyamides, polyvinylchlorides, polyketones, polysulfones,polycarbonates, fluoropolymers, polyacrylates, polyurethanes,co-polyetheresters, polypropylenes, and co-polyetheramides. The outershell fabric and inner lining fabric can have any desired color andtexture (e.g., it can have a camouflage pattern or it can be infrared ornear-infrared absorptive or reflective), and can be dyed or impregnatedas needed to achieve a desired appearance or functionality, such aswater repellency (DWR). The outer shell fabric or inner lining fabricmay contain Lycra® or another elastic fiber to create stretchcharacteristics. Lycra®, also known as spandex or elastane, is apolyurethane polyurea copolymer that can be woven into a fabric, such asan outer shell fabric, a liner fabric, or a seam tape fabric to provideelasticity. Alternatively, elasticity or stretch can be provided byusing a woven or non-woven fabric having stretch in at least onedirection. It is preferred that the outer shell fabric, lining fabric,and any seam tape fabric provide a similar or essentially identicaldegree of stretch, for optimum comfort and non-restrictive feel of thegarment. A fleece fabric can be any fleece, such as a fleece made ofPET, and can have any texture, color, or thickness as desired or asappropriate for a particular garment. The fleece is preferablyinsulating, breathable, and soft to the touch. Chemical substances suchas flammability retarding agents can be also added.

The type and quantity of yardage of the membrane barrier films areselected as required for the fabric product being produced. The membranebarrier films, described in the processes herein can include a“hydrophobic polymer membrane” or “hydrostatic barrier membrane,” whichtypically refers to a layer of synthetic or natural polymers thatresists the passage of liquid water, in the form of droplets ormicrodroplets, across the membrane. Preferably, the hydrophobic polymermembrane allows the passage of water vapor, in the form of individualwater molecules, so as to promote breathability of the laminated fabric.A hydrophobic polymer membrane can be prepared from a material such asmicroporous or nanoporous polytetrafluoroethylene (PTFE), expanded PTFE(ePTFE), polyurethane, cross-linked polyurethane, polypropylene, orpolyester. One example of a waterproof laminated fabric is Gore-Tex®fabric (see, e.g., U.S. Pat. No. 3,953,566), which utilizes a porousPTFE membrane as the hydrophobic polymer membrane. The PTFE membrane ofa GoreTex® fabric has a microstructure characterized by nodesinterconnected by fibrils. The microporous or nanoporous nature of thePTFE membrane is such that water droplets are excluded from the pores,whereas water molecules can pass through the pores. Another example of amembrane barrier film is the fabrics available from Cocona Technology,which incorporate activated carbon particles with microporous structuresinto the films. The membrane barrier films can include patterns printedon one side, for example, by a transfer printing process, which isparticularly useful for lighter garments that do not also include aseparate lining fabric. The membrane barrier film can also be printedwith a coating, for example, to provide protection from abrasion.

The insulation is selected to provide the specific type and weight of acontinuous or discontinuous filament insulation or equivalent and in thequantity required for the fabric product being produced. An insulatingmaterial can include a natural or synthetic material that providesthermal insulation. Insulating material can be made of synthetic loftedcontinuous filament insulation such as Climashield® Apex by HarVestConsumer Insulation, or Thinsulate™ microfibers by 3M. Insulatingmaterial is preferably lightweight and breathable, and can be made fromfibers that can be hydrophobic or hydrophilic, fire retardant, flexible,and obtained from recycling or from a renewable fiber. One or morelayers of fabric, such as a fleece or other non-containable fabric, or atricot, can also be used as an insulating material.

A non-containable fabric refers to a fabric that does not allowsaturation of the spaces between fibers of the fabric by an adhesive tocreate a hydrostatic seal. A non-containable fabric generally has alarge volume of open space between microfibers of the fabric. Examplesof a non-containable fabric include fleece and other insulatingmaterials.

A fleece refers to a pile fabric, including woolen fabrics as well assynthetic fabrics. Fleece be made of or derived from natural fiber suchas wool or a synthetic polymer, such as polyethylene terephthalate (PET)(e.g., Polarfleece® by Polartec, LLC). Fleece is typically lightweight,insulating, hydrophobic, and breathable, i.e., allowing water vapor topass through. Pile fabrics are made by dying loose fibers, which arethen mixed and combed into a long rope that is guided into a knittingmachine, which permanently locks the fibers into a backing. The fabricis then sheared and finished. A pile results from the individual fibersstanding on end. Fleece is made by first twisting fibers into a yarn,which is then knitted into a fabric. The fabric is then brushed,sheared, and finished.

The specific type and weight of the adhesive composite is selected forthe type of fabric product being produced. The adhesive can be selectedto withstand any laundering processes that the fabric product mayundergo, such as washing, drying, dry cleaning, and ironing. The amountof adhesive can be increased or decreased as required by the type ofouter shell fabric, membrane barrier film and inner lining fabriccombination. The adhesives include powdered adhesives, web adhesives,micro-dot or nano-dot adhesives. Suitable adhesives can includepolyurethane adhesives. Adhesives are typically measured in grams persquare yard. The process can reduce a negative impact on the moisturevapor transmission rate (MVTR) over the membrane barrier film surface,by reducing the use of adhesives over the area of the membrane barrierfilm surface. The adhesives can be applied in a discontinuous pattern,such as in a dot, line, or grid pattern, or in no regular pattern, tominimize the amount of adhesive. Suitable adhesives are commerciallyavailable from various suppliers such as Bostik.

In another aspect, an individualized design application process isprovided to create a garment that is specifically designed for aparticular application. For example, a garment can be designed for aparticular sport, such as skiing. A garment can be designed to addressindividual sizing problems, such as longer sleeve requirements.Individually-designed garments may have specific needs, such as aparticular zipper placement, or specific performance panels. Specificperformance panels can include, for example, a moisture barrier inselected areas of a garment, rather than throughout the entire garment.Similarly, insulation can be added in selected areas of a garment, orinsulation of different weights can be located in different areas of thegarment.

The process provides for the production of an individual garment withgreat versatility and little set-up time & lead time, while reducingcosts that are associated with current custom manufacturing assemblyprocesses. The outer shell fabrics are accessible in the separategarment make-up step, which allows the outer shell fabric pattern to bealtered to accommodate varied panels of laminated & un-laminatedfabrics. The variable inner and outer zone area panels can be the samesize and shape to allow for invisible barrier seams to be aligned duringthe fusing process if desired. See US 2012/0282425. Seams can be eitherstraight or curved, and the fabric pieces joined can have any shape orform as required for a particular garment piece. Two or more pieces offabric can be joined to form a seam.

Referring to FIG. 1, a multi-layer fabric product 10 is formed form atleast an outer shell fabric 12 and a barrier layer 14. The outer shellfabric can be any suitable fabric, depending on fabric product, asdescribed above. The barrier layer can be a moisture barrier or athermal barrier, also as described above.

An adhesive layer 16 is interposed between the outer shell fabric andthe barrier layer. The adhesive can be pre-applied on the barrier layeron the side adjacent the outer shell fabric. In other embodiments, anadhesive can be pre-applied to the opposite or interior-facing side ofthe barrier layer, for example, if additional layers are included in thefabric composite, as discussed further below. Exemplary adhesivesinclude a web adhesive, a powder adhesive, a micro-dot adhesive, and anano-dot adhesive. In one alternative, a web adhesive can be used as thebarrier layer.

In an alternative, described further below, the barrier layer can be amulti-layer thermoplastic composite, thereby eliminating the requirementfor additional adhesives or decreasing the amount of adhesives that arerequired.

The fabrication steps for a two-layer fabric product with matching seamsare as follows:

1) Roll out the outer shell fabric 12, the barrier layer 14, and theinterposed adhesive layer 16 onto a pattern cutting machine. Preferably,a pattern cutting machine that can cut multiple stacked layers of fabricis used, such as a Gerber pattern cutting machine. Cut out the fabricpattern panels (FPPs).

2) Remove the outer shell FPPs 18 and sew or ultrasonically weld anyrequired findings, such as hoods, pockets, zippers, etc., into position.Position a moisture resistant adhesive seam tape where required, forexample, along the zippers, using a thermal process.

3) Align each of the partially finished outer shell FPPs 18 to itscorresponding barrier layer FPP 20 and adhesive FPP 22, creating thefull composite FPPs 24. See FIG. 2. FIG. 2 schematically illustrates twocomposite FPPs. It will be appreciated that the number of FPPs dependson the particular fabric product. For example, a jacket can have FPPsfor front panels, back panels, side panels, and sleeves.

4) Fuse each of the full composite FPPs 24 together to create the fabricpanel pattern alignment using either a soft set or a hard set. A softset allows the barrier layer to be peeled back without damaging thesurface structures. A hard set permanently sets the layers in place. Anarea 26 around the perimeter of the panel is left unfused, which allowsthe barrier layer FPP 20 and adhesive layer FPP 22 to be folded backwithout damaging the surface structures. The width of the area leftunfused can be at least ½″ in width or greater. In some embodiments, thewidth of the unfused area can be at least ⅝″, ¾″, 1 inch, 2, inches, 3inches, or greater. See FIG. 3.

When fusing fabric layers with a soft set fuse, the press is set to atemperature of approximately 225° F. at zero pressure to allow theadhesive to flow to create an initial bond between the surfaces. Thisinitial bond allows the individual layers to be pulled away from theother layers. When fusing fabric layers with a hard set fuse, the pressis set to a temperature between 235° F. to 275° F. at 40 psi to 50 psifor 20 to 40 seconds. After pressing, the composite fabric is cooledunder vacuum to set the adhesives into place and permanently laminatethe fabric panels together.

5) Fold back the barrier layer FPP 20 and the adhesive layer FPP 22 toexpose the surface of the outer shell fabric 18. See FIG. 4.

6) Seam the outer shell fabric pattern panels together to provide a seam28 along the exposed edges, for example, by sewing or ultrasonicallywelding, to assemble the outer shell of the fabric product. See FIG. 4.The barrier layer is not compromised, as it is held in position adjacentthe outer shell by the adhesives and the edges of the barrier layer arefolded over onto itself, out of the way of the seaming.

7) Fold the barrier layer and the adhesive layer (if present back overthe outer shell seam taped garment, so that the unfused areas 26overlap. See FIG. 5.

8) Fuse the assembled layers together, including the unfused areas 26,to complete the lamination process and form the complete fabric product.This creates a uniform barrier layer throughout the complete fabricproduct. Moisture and thermal leakage pathways are eliminated andstrengthened seams are provided in the finished fabric product.

The fusion process can employ a three-dimensional form finisher, such asa VEIT 8363 Basic Multiform finisher. A three-dimensional form finisheremploys a dummy form over which a fabric product such as a garment isdisposed. Heat and steam are introduced through the interior, applyingpressure that inflates the garment outwardly and fuses all the layerstogether. Another example is the Dressman ironing robot from Siemens. Touse such a finisher or robot, the garment is placed over the robot,which is then inflated to fit the garment from the inside, applyingpressure. The robot is then filled with heated air or steam, whichapplies heat to the entire garment. Alternatively, a conventional steamironing table could be used to carry out alignment lamination.

In another aspect, the seams in the outer shell do not need to alignwith seams in the barrier layer. See FIG. 6. For example, sides 18A, 18Cand back 18B of the outer shell of a garment such as a jacket can be cutout as separate FPPs and seamed together to create a single large panelthat can lay flat. The barrier layer FPP 20 and adhesive layer FPP 22can be cut out as a single large panel that matches the perimeter of theseamed single large panel of the outer shell. In this case, the outershell fabric is rolled out and cut separately from the barrier layer andadhesive layer. Then the barrier layer and adhesive layer are positionedon the inner surface of the outer shell FPP and fused, leaving the edgesaround the perimeter unfused, as described above. Because this assemblycan lay flat, a two-dimensional pressing machine, such as VEIT BRI-2001E/101 pressing machine, can be used. The barrier layer fully covers theseams 28 in the outer shell, leading to a continuous, uniform barrieracross the outer shell.

Many fabric products incorporate three or more layers. For example, inone embodiment, a multi-layer fabric composite is formed from multiplelayers including an outer shell fabric, an inner lining fabric, and asthe barrier layer, a membrane barrier film as a moisture barrier betweenthe outer shell fabric and the inner lining fabric. See FIG. 7. Theinner lining fabric can be an insulating fabric, such as a fleece, or anun-insulating fabric, such as a tricot. Alternatively, the barrier layercan be an insulation package of a continuous or discontinuous filamentinsulation or equivalent. See FIG. 8. In a further alternative, inaddition to a membrane barrier film, an insulation package can beprovided adjacent an interior side of the inner lining fabric. See FIG.9. A suitable adhesive layer can be interposed between each of thelayers as needed.

The fabrication steps for a three-layer or four-layer fabric compositewith matching seams and employing as the barrier layer a membrane filmand, optionally, an insulation package in addition to the membrane film,are as follows:

1) Roll out the outer shell fabric, membrane film, and any adhesivelayers, the insulation package (if present), and the inner lining fabriconto a pattern cutting machine, such as a Gerber pattern cutting machineor equivalent, and cut out the garment fabric pattern panels (FPPs).

2A) Remove the outer shell FPPs and sew or ultrasonically weld anyrequired findings, such as hoods, pockets, zippers, etc., into position,and position an adhesive seam tape film where required through a thermalprocess.

2B) Remove the inner lining FPPs and sew or ultrasonically weld anyrequired findings, such as zippers, pockets, etc. into position.

3) Align the partially finished outer shell and partially finished innershell FPPs to the matching membrane film FPP, and the insulation package(if present), creating the full composite FPPs. Position the adhesivelayer(s) on the appropriate side of the membrane barrier film (if notalready laminated to the membrane barrier film).

4) Fuse the full composite FPPs together to create the fabric panelpattern alignment using either a soft set or a hard set leaving an areaaround the perimeter of the panel unfused, as described above.

5) Fold back the membrane film, the adhesive layer or layers, theinsulation package (if present), and the inner lining fabric at theunfused areas to expose the outer shell fabric surface.

6) Seam the outer shell fabric pattern panels together along the exposededges, for example, by sewing or ultrasonically welding, to assemble theouter shell of the fabric product. The membrane barrier film (andinsulation package if present) is not compromised, as it is held inposition adjacent the outer shell by the adhesives and the edges of themembrane barrier film are folded over onto itself, out of the way of theseaming. It is not necessary to attach an adhesive seam tape to the seamat this step (although it could be done if desired; see US2012/0282425).

7) Fold the membrane barrier film, the adhesive layer(s), the insulationpackage (if present), and the inner lining fabric back over the outershell seam taped garment, so that the seam allowances overlap. See FIG.10 or 11 (in which the adhesive layers have been omitted for clarity).

8) Seam the inner lining FPP composite together along the seam surface,for example, by sewing or ultrasonic welding. The unfused area of theinner lining FPP can be pulled away from the other layers as needed toform the seam.

9) Fuse the assembled garment, product or sub assembly product tocomplete the lamination process, as described above. The laminationprocess can be accomplished by applying a heat and/or pressure sourceover a large area of the assembled garment, or over the entire garmentat once. This final step of alignment lamination creates a stronglaminate bond between the fabrics of the garment.

This creates a uniform membrane barrier film layer throughout thecomplete garment assembly, eliminating leakage pathways through themoisture barrier and providing strengthened seams in the garment,product, or sub-assembly product.

It will be appreciated that a three-layer fabric product incorporatingonly an insulation layer can be fabricated as described above for athree-layer product incorporating only a membrane barrier film.Similarly, additional layers can be included and can be handled in thesame manner as the barrier layer or insulation package described above.

In a variant of the fabrication process for a multi-layer fabriccomposite with matching seams, the steps are as follows, in which steps1-4 are as described above:

5) Fold back the composites of the inner lining fabric and adjacentlayer(s) of adhesive to expose the outer shell fabric, the membranefilm, and the interposed adhesive layer (if present).

6) Seam the outer shell fabric, the adhesive layer (if present) and themembrane barrier film together to create the outer shell garment. Whilethe membrane film surface is exposed, position an adhesive seam tapefilm where required through a thermal process.

7) Fold the inner lining fabric back over the outer shell garment.

8) Seam the inner liner fabric panel together along the seam surface,for example, by sewing or ultrasonic welding.

9) Fuse the assembled garment, product or sub assembly product tocomplete the lamination process, as described above.

For a fabric product in which the seams between the outer shell fabricand one or more of the other layers are offset, rather than matched, thefollowing steps are followed:

1A) Roll out the outer shell fabric onto a pattern cutting machine, suchas a Gerber pattern cutting machine or equivalent, and cut out theoffset outer shell fabric composite of the garment fabric pattern panel.

1B) Roll out the adhesive layer (if present), the membrane film, furtheradhesive layer (if present), the insulation package (if present), andthe inner lining fabric composites onto a pattern cutting machine, suchas a Gerber pattern cutting machine or equivalent, and cut out theoffset composites of the garment fabric pattern panels.

2A) Remove the outer shell fabric pattern panels and sew orultrasonically weld the required findings, i.e. hoods, pockets, zippers,etc. into position.

2B) Remove the inner lining fabric pattern panels and sew orultrasonically weld the required findings, i.e. zippers, pockets, etc.into position.

3) Align the partially finished outer shell and partially finished innershell fabric pattern panels, the membrane film, the adhesive layer(s),and the insulating package (if present), creating the full offset fabricpattern panel composites.

4) Fuse the full composite fabric pattern panels together to create thefabric panel pattern alignment using either a soft set or a hard set,leaving an area around the perimeter unfused, as described above.

5) Fold back the membrane film, the adhesive layer(s), the insulationpackage (if present), and the inner lining fabric at the unfused areasto expose the outer shell fabric surface.

6) Seam the outer shell fabric pattern panels together, for example, bysewing or ultrasonic welding, to assemble the outer shell garment,product, or sub-assembly product.

7) Fold membrane film, the adhesive layer(s), the insulation package (ifpresent), and the inner lining fabric back over the outer shell garment.

8) Seam the inner liner fabric panel composite together along the seamsurface, for example, by sewing or ultrasonic welding.

9) Fuse the assembled garment, product or sub assembly product tocomplete the lamination process, as described above.

In a variant of the fabrication process for a multi-layer fabriccomposite with offset seams, the steps are as follows, in which steps1-4 are as described above:

5) Fold back the composites of the inner lining fabric and adjacentlayer of adhesive (if present) to expose the outer shell fabric, themembrane film, and the interposed adhesive layer (if present).

6) Sew or ultrasonically weld the outer shell fabric, the adhesive layer(if present), and the membrane film together to create the outer shellgarment. While the membrane film surface is exposed, position anadhesive seam tape through a thermal process.

7) Fold over the inner lining fabric and the adjacent adhesive layer (ifpresent) back over the outer shell garment, product, or sub-assemblyproduct.

8) Seam the inner liner fabric pattern panel together along the seamsurface, for example, by sewing or ultrasonic welding.

9) Fuse the assembled garment, product or sub assembly product tocomplete the lamination process, as described above.

Some garments include one or two quilted insulation packages. Forexample, a quilted insulation package can be the outside of the garment,the inside of the garment, or on both the outside and inside of thegarment. The quilting can provide a desirable aesthetic appearance inaddition to incorporating thermal insulation into the garment. However,the stitching used to quilt the layers of the insulation package alsocauses small perforations through which heat loss occurs. Thus, anadditional continuous thermal barrier can be provided to reduce thisheat loss through the quilted stitches.

Referring to FIG. 12, one example of a quilted garment is fabricatedfrom layers including an outer shell fabric, an outer shell insulationpackage, an lining inner insulation package, an inner lining fabric, andan intermediate barrier layer insulation package. The insulationpackages can be formed from a continuous or discontinuous filamentinsulation or equivalent. Separate adhesive layers can be interposedbetween the outer insulation package and the intermediate insulationpackage and between the inner insulation package and the intermediateinsulation package. The adhesive layers can be a micro-dot adhesive, apowder adhesive or a web adhesive. The adhesive layers can bepre-applied to the insulation packages.

The fabrication steps for a quilted fabric product are as follows:

1A) Quilt together the outer shell fabric, outer shell insulationpackage, and adhesive layer (if present) in a desired quilting patternor motif to create an outer quilted composite. Similarly, quilt togetherthe inner lining fabric, the inner lining insulation package, andadhesive layer (if present) in a desired quilting pattern or motif tocreate an inner quilted composite. If necessary, fuse an adhesive layerto one or both sides of the intermediate barrier layer insulationpackage.

1B) Roll out the outer quilted composite, the barrier layer insulationpackage, and the inner quilted composite above onto a pattern cuttingmachine, and cut out the fabric pattern panels.

2A) Remove the outer quilted fabric pattern panel composites and sew orultrasonically weld the required findings, i.e. hoods, pockets, zippers,etc. to complete the assembly.

2B) Remove the inner quilted fabric pattern panel composites and sew orultrasonically weld the required findings, i.e. zippers, pockets, etc.into position.

3) Align each of the partially finished outer quilted composites and theinner quilted fabric composites to the corresponding barrier layerinsulation packages, creating the full FPP composites.

4) Fuse the full FPP composites together to create the fabric panelpattern alignment using either a soft set or a hard set, as describedabove.

5) Fold back the barrier layer insulation packages and the inner quiltedcomposites to expose the interior side of the outer quilted composite.

6) Sew or ultrasonically weld the outer quilted composite FPPs togetherto assemble the outer shell of the fabric product.

7) Fold the barrier layer insulation package and the inner quiltedcomposites back over of the outer quilted composite the seam allowancesoverlap.

8) Sew or ultrasonically weld the inner quilted composites togetheralong the seam surface.

9) Fuse the assembled layers together to complete the laminationprocess. This creates a uniform insulation layer of a continuous ordiscontinuous filament insulation or equivalent throughout the completefabric product, eliminating thermal heat loss through the outer shellseams and quilting stitches and a thermal heat gain next to the body.

Garment Assembly Example 1

As an example, the above fabrication steps can be used in thefabrication of a garment such as a waterproof/breathable (WP/BR) jackethaving an outer shell, a membrane film barrier layer, and inner lining,as follows:

1) Roll out the outer shell fabric, the adhesive layer (if the adhesivehas not been pre-applied), the membrane film, the adhesive (if theadhesive has not been pre-applied), and the inner lining fabriccomposite onto a pattern cutting machine and cut out the garment fabricpattern panels. Optionally, the inner lining fabric pattern does nothave to be matched to the outer shell fabric pattern.

2) Remove the outer shell fabric, the adhesive, the membrane film, andthe adhesive pattern panels and sew or ultrasonically weld and seam tapethe back, sides and front panels of the garment assembly; add anyrequired findings, i.e. zippers, pockets, etc. into position topre-finish the outer shell garment assembly.

3) Take the inner lining fabric pattern panels and sew or ultrasonicallyweld the garment assembly as necessary.

4) Optionally sew in and seam tape a zipper and a collar assembly.

5) Position the inner lining fabric pattern panel garment assembly ontop of the fabric pattern panel two-layer laminate garment assembly toform a fabric pattern panel garment pattern assembly.

6) Fuse the fabric pattern panel garment pattern assembly together witha hard set, leaving an unfused area around the perimeter to allow theinsertion of the zipper, collar, sleeve areas and the hem line.

7) For each sleeve, lay out the sleeve fabric pattern panels, which arethe outer shell laminate and inner lining.

8) Position the inner lining fabric pattern panel sleeve on top of theouter shell laminate fabric pattern panel sleeve and membrane barrierfilm to form a fabric pattern panel sleeve pattern assembly.

9) Hard set flat press leaving an unfused area around the perimeter toallow the insertion and finishing of the sleeve assemblies.

10) Sew and seam tape the FPP sleeve assemblies to the FPP garmentpattern assembly.

11) Sew and seam tape the zipper and collar assembly (if not performedin the garment assembly step above).

12) Ultrasonically weld or sew the open flaps of the inner lining fabricseams to complete the sleeve and shoulder seam surfaces.

13) Hard set press the non-pressed open flap seam surfaces to completethe pressing of the FPP garment pattern assembly.

Garment Assembly Example 2

As another example, the above fabrication steps can be used in thefabrication of a garment such as an insulated, WP/BR jacket having anouter shell, a membrane film barrier layer, an insulation package, andan inner lining, as follows:

1) Roll out the outer shell fabric, the web adhesive (if the adhesive isnot pre-applied), the membrane film, the adhesive (if the adhesive isnot pre-applied), and the inner lining fabric composite onto a patterncutting machine, and cut out the garment fabric pattern panels.Optionally, the inner lining fabric pattern panel does not have to bematched to the outer shell fabric pattern panel.

2) Roll out the insulation package and the optional adhesive and cut outin a single piece construction matching the sewn inner lining fabricpattern panel assembly.

3) Remove the outer shell, web adhesive (if present), membrane film, andweb adhesive (if present) fabric pattern panels and sew orultrasonically weld and seam tape the back, sides and front panels ofthe garment assembly. Add any desired findings, i.e. zippers, pockets,hood, etc., into position to pre-finish the outer shell garmentassembly.

4) Take the inner lining fabric pattern panel and sew or ultrasonicallyweld the inner lining garment assembly. Optionally sew in and seam tapethe zipper and the collar assembly.

5) Position the inner lining fabric pattern panel garment compositeassembly on top of the prefabricated outer shell fabric pattern panelassembly, the FPP garment pattern assembly.

6) Hard set flat press the FPP garment pattern assembly leaving anunfused area around the perimeter to allow the insertion of the zipper,collar and sleeve areas.

7) For each sleeve, lay out the sleeve fabric pattern panels, which arethe outer shell laminate, insulation, and inner lining.

8) Position the insulation and the inner lining sleeve fabric patternpanels on top of the outer shell laminate fabric pattern panel sleeve,forming an FPP sleeve pattern assembly.

9) Hard set flat press leaving an unfused area around the perimeter toallow the insertion and finishing of the sleeve assemblies.

10) Sew and seam tape the FPP sleeve pattern assemblies to the FPPgarment pattern assembly.

11) Sew and seam tape the zipper and collar assembly (if not performedin the garment assembly procedure above).

12) Fold over and position the insulation layer over the seam taped seamsurface.

13) Ultrasonically weld or sew the open flaps of the inner lining fabricseams to complete the sleeve and shoulder seam surfaces.

14) Hard set press the non-pressed open flap seam surfaces to completethe pressing of the FPP garment pattern assembly.

Garment Assembly Example 3

The process as above in Example 2 can be used with a multi-layercomposite formed of individual parts, where seam tape would not berequired in the sleeve and the shoulder seams:

Steps 1 through 6 are the same as above in Example 2.

7) For each sleeve, lay out and cut out the outer shell fabric, webadhesive, membrane film, web adhesive, optional insulation, optional webadhesive, and inner lining fabric pattern panels.

8) Position the inner lining fabric pattern panel sleeve assemblies, theoptional web adhesives, the optional insulation on top of the outershell laminate fabric pattern panel sleeve assembly to form each FPPsleeve assembly.

9) Hard set flat press leaving an unfused area around the perimeter toallow the insertion and finishing of the sleeve assemblies.

10) Sew the outer shell fabric pattern panel sleeve to the FPP garmentpattern assembly.

11) Sew and seam tape the zipper and collar assembly (if not performedin the garment assembly procedure above).

12) Fold over and position the web adhesive, membrane film, webadhesive, insulation fiber layer, web adhesive over the sewn outer shellfabric seam surface.

13) Ultrasonically weld or sew the open flaps of the inner lining fabricseams to complete the sleeve and shoulder seam surfaces.

14) Hard set press the non-pressed open flap seam surfaces to completethe pressing of the FPP garment pattern assembly.

A variety of fabric products can be fabricated by the process of thepresent invention. Such fabric products include garments or articles ofclothing, such as jackets, coats, parkas, raincoats, cloaks, ponchos,shirts, blouses, pants, shoes, boots, gloves, hats, hoods, or otherheadwear, or underwear such as undershirts, briefs, bras, socks, anddiapers. Fabric products can also include protective suits for handlingof hazardous materials, including chemicals, biological materials, andradioactive materials, or in protective suits for firefighters, militarypersonnel, and medical personnel. Other fabric products includeblankets, towels, sheets, pet bedding, tents, sleeping bags, tarps, boatcovers, carpeting, rugs, mats, window coverings, and upholstery, and anyfabric-based structure or device that serves to entrap, store, ortransport water or an aqueous liquid, such as bags, hoses, or bladders,or where thermal insulation is needed.

Machines for performing cut/weld seaming operations using ultrasound areknown and commercially available. For example, the firm Jentschmann, AG(Huntwangen, Switzerland) provides a variety of suitable machines. Theultrasound energy applied during seaming can be adjusted according tothe needs of the particular seam, including the characteristics of thefabrics and the adhesive. Welding conditions depend on conditions oftemperature and humidity and the type of fabric, hydrostatic barriermembrane, and fleece. Ultrasonic machines are available which simplyweld fabrics together as well as those which cut fabrics in addition towelding them. Adjusting an ultrasonic fabric welding machine accordingto such conditions is well within the capabilities of the ordinaryskilled person. It is understood that an ultrasonic welding or cuttingand welding machine can be used to carry out methods of the invention indifferent modes. In addition to ultrasound, other sources of energy thatcan be used to perform a seam welding operation include heat energy,laser energy, and other forms of electromagnetic radiation (e.g.,microwave or radio frequency).

Several known methods are available for testing the hydrostaticresistance properties of a fabric product fabricated according to thepresent invention. These include ASTM Standard D 5385, 1993(2014)E1,“Standard Test Method for Hydrostatic Pressure Resistance ofWaterproofing Membranes,” ASTM International, West Conshohocken, Pa.,DOI: 10.1520/D5385 D5385_M-93R14E01. In one example, a fabric productaccording to the invention has a hydrostatic resistance of at least 1,2, 3, 4, or 5 psi for 3 minutes using ASTM D 5385. In another example, afabric product according to the invention has a hydrostatic resistanceof at least 3 psi for 3 minutes using ASTM D 5385. In some embodiments,a fabric product according to the invention has a hydrostatic resistanceof at least 1, 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, 45, or 50 psi.

Hydrostatic resistance can also be tested in accordance the HydrostaticResistance test method described in ASTM D751, 2006(2011) “Standard TestMethods for Coated Fabrics,” ASTM International, West Conshohocken, Pa.,DOI: 10.1520/D0751-06R11. In some embodiments, a fabric productaccording to the invention has a hydrostatic resistance of at least 1,2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, 45, or 50 psi.

The fabric product can also be tested by a test method to evaluate thebarrier effectiveness against liquids. Such test methods include ASTMF903, 2010, “Standard Test Method for Resistance of Materials Us inProtective Clothing to Penetration by Liquids,” ASTM International, WestConshohocken, Pa., DOI: 10.1520/F0903-10. The fabric product can betested as a barrier against various compounds, such as foams (forexample, aqueous fire fighting foams), hydraulic fluids, battery acid(which includes sulfuric acid, for example, 37%), pool chlorine, andfuels (for example, Fuel C).

As another example, the fabric product can be tested to see if it passesa test for resistance to synthetic blood as determined by ASTM F1670,2008(2014)E1, “Standard Test Method for Resistance of Materials Used inProtective Clothing to Penetration by Synthetic Blood,” ASTMInternational, West Conshohocken, Pa., DOI:10.1520/F1670_F1670M-08R14E01. A further test is to determine if thefabric product passes a test for resistance to pathogenicmicro-organisms, including blood borne pathogens as determined by ASTMF1671, 2013, “Standard Test Method for Resistance of Materials Used inProtective Clothing to Penetration by Blood-Borne Pathogens UsingPhi-X174 Bacteriophage Penetration as a Test System,” ASTMInternational, West Conshohocken, Pa., DOI: 10.1520/F1671_F1671M.

A variety of adhesives are commercially available and can be used as theadhesive layer(s) described above. As noted above, an adhesive, such asa web adhesive, a powder adhesive, or a micro-dot adhesive, can bepre-applied on one or both sides of the membrane barrier film or theinsulation package. In one alternative, a web adhesive can become themembrane barrier film. Generally, the least amount of adhesive necessaryshould be used to avoid blocking the micro pores of the barrier membranefilm and reduce the moisture vapor transport rate (MVTR). A powderadhesive is best suited to have the least impact on the MVTR of themembrane barrier film. Micro dot adhesives typically decrease the MVTRof the membrane barrier film the greatest amount.

In one trial, the MVTR of a laminate employing a stretch fabric, amembrane barrier film, and a fleece lining, employing several adhesivesfrom Bostik was measured and compared to the MVTR of the membranebarrier film alone. The following results were obtained:

MVTR Percent reduction Sample Adhesive (g/m²/24 hours) in MVTR A Bostikpowder 536 20% B PE103 15G web adhesive 498 26% C PE103 25G web adhesive482 28%

In a further alternative, the membrane barrier film can be a multi-layerthermoplastic composite, thereby eliminating the requirement foradditional adhesives or decreasing the amount of adhesives that arerequired.

In another aspect of the present invention, a low melt membrane film canbe provided on one or both sides of a high melt membrane film, for useas a moisture barrier in a garment, to enhance the subsequent adhesionof the membrane barrier film to another layer by a chemical and thermalmechanical bond. The low melt film melts at lower temperatures,providing adhesion at reduced temperatures. This can be useful, forexample, for temporary adhesion during a garment fabrication process orfor tacking one substrate to another prior to forming a more permanentattachment between the substrates. Also, the presence of the low meltmembrane film allows for a reduction in the amount of additionaladhesives, such as micro-dot, powdered, or web adhesives, that wouldotherwise be needed, which can reduce the cost of the membrane film. Forexample, the melting temperature of the high melt membrane film can be,for example, 5, 10, 15, 20, 30, 40, or 50° C. or more higher than themelting temperature of the low melt membrane film.

In some garments that employ a moisture barrier layer, the barrier layeris provided by a breathable thermoplastic polyurethane (TPU) membranefilm as the primary barrier layer. Usually, the TPU membrane film has ahigh melt temperature rating. A low melt TPU membrane film can be addedon one or both sides of the high melt TPU membrane film as one or moreouter layers to enhance the chemical and thermal mechanical bondsurfaces. For example, a low melt TPU membrane film can subsequentlyreact as an adhesive in other portions of the garment fabricationprocess, such as when an invisible barrier seam is formed, as describedUS 2012/0282425. The low melt TPU membrane film can react with theadhesive used in these subsequent fabrication steps, creating a higherquality adhesion bond. Because of the adhesion qualities of the low meltTPU membrane films, operator error can be reduced, and the upper andlower heat and pressure bounds during the pressing sequences of thefabrication process can be expanded.

Additionally, it will be appreciated that TPU membrane films can havedifferent melt temperatures. Thus, a TPU membrane film having a firstlow melt temperature can be provided on one side of a substrate, and afurther TPU membrane film having a different, lower, melt temperaturecan be provided on the opposite side of the substrate. For example, thetwo low melt films can have different degrees of cross-linking.

The low melt membrane film can be formed from a variety of suitablematerials, such as a polyester, polyether, polypropylene or apolyurethane material. The film can be breathable or non-breathable.

The high melt membrane film can also be formed from a variety ofsuitable materials, such as a polyester, polyether, polypropylene,polyurethane, expanded polytetrafluoroethylene (ePTFE) or apolytetrafluoroethylene material. The high melt film can be breathableor non-breathable. The high melt membrane film can be a single pass,single ply high melt membrane film as described in Example 3.

In a fabrication process, the low melt membrane film(s) and high meltmembrane film can be fed from spools onto a conveyor belt and introducedinto a suitable heated lamination machine. Alternatively, one or more ofthe films can be provided from suitable extrusion dies. Additionally,during the fabrication process, chemical additives can be compoundedwith one or more of the membrane films in a liquid or plastic form (forexample, through an extrusion die) or applied from hoppers, nozzles, orother dispensers onto the films in substrate form. In a furtheralternative, the low melt membrane film can be die cut into smallerpieces or an open pattern to reduce the surface area of the high meltmembrane film that is covered by the low melt membrane film.

In one example, a multi-layer TPU/ePTFE membrane layout includes a highmelt ePTFE breathable barrier membrane film, and a low melt TPUbreathable membrane film on one or both surfaces. The TPU films on theouter surfaces can be selected to have different melt temperatures,i.e., a low melt TPU and a lower melt TPU.

The composite membrane film as described herein can be used as amoisture barrier in fabric products such as garments. Various woven,non-woven, or knit outer shell fabrics can be selected and fused to themembrane barrier film outer surface. Similarly, various woven or knitinner lining fabrics can be selected and fused to the membrane barrierfilm inner surface. The composite membrane film can be fed directly tothe fabric, or the composite membrane film can be stored, for example,rolled on a spool, for subsequent use. Completion of the laminationprocess occurs during the remainder of the garment manufacturingprocess.

In some cases, one of the films can be a single ply membrane film aftera single pass through an extruder that may not be commercially viabledue to the presence of pin holes. Laminating the single pass film to theother layers effectively fills the pinholes. By providing more usablematerial, waste is eliminated and cost reductions can be realized infabrication processes for various fabric products that employ membranefilms.

It will be appreciated that the various features of the embodimentsdescribed herein can be combined in a variety of ways. For example, afeature described in conjunction with one embodiment may be included inanother embodiment even if not explicitly described in conjunction withthat embodiment.

The present invention has been described with reference to the preferredembodiments. It is to be understood that the invention is not limited tothe exact details of construction, operation, exact materials orembodiments shown and described, as obvious modifications andequivalents will be apparent to one skilled in the art. It is believedthat many modifications and alterations to the embodiments disclosedwill readily suggest themselves to those skilled in the art upon readingand understanding the detailed description of the invention. It isintended to include all such modifications and alterations insofar asthey come within the scope of the present invention.

What is claimed is:
 1. A multi-layered fabric product comprising: anouter shell fabric comprising a plurality of fabric pattern panels, atleast one seam formed along edges of fabric pattern panels to join thefabric pattern panels together, the outer shell fabric having an innerside and an outer side; a barrier layer comprising a plurality ofpattern panels fused to the inner side of the outer shell fabric, thepattern panels overlapping in an area extending along the seam of theouter shell fabric, wherein the barrier layer extends across the innersurface of the outer shell fabric and the at least one seam between theouter shell fabric pattern panels.
 2. The product of claim 1, whereinthe at least one seam comprises a sewn seam or an ultrasonically weldedseam.
 3. The product of claim 1, wherein the barrier layer comprises ahydrophobic polymer membrane.
 4. The product of claim 3, wherein thehydrophobic polymer membrane comprises a material selected from thegroup consisting of microporous polytetrafluoroethylene (PTFE),nanoporous PTFE, expanded PTFE, polyurethane, cross-linked polyurethane,polypropylene, and polyester.
 5. The product of claim 1, wherein thebarrier layer comprises activated carbon particles with microporousstructures.
 6. The product of claim 1, wherein the barrier layer iscapable of withstanding a hydrostatic pressure of at least 1 psi,including across the at least one seam.
 7. The product of claim 6,wherein the barrier layer is capable of withstanding a hydrostaticpressure of at least 45 psi, including across the at least one seam. 8.The product of claim 1, wherein the barrier layer is equally resistantto hydrostatic pressure across the inner surface of the outer shellfabric and the at least one seam.
 9. The product of claim 1, wherein thebarrier layer is resistant to at least one of pathogenic microorganisms,blood borne pathogens, viruses, bacteria, liquid chemical agents, andgaseous chemical agents.
 10. The product of claim 1, wherein the barrierlayer is resistant to heat loss.
 11. The product of claim 1, wherein thebarrier layer comprises an insulation material.
 12. The product of claim11, wherein the insulation material comprises a natural or syntheticfilament material.
 13. The product of claim 1, further comprising aninner lining fabric pattern panel fused to the barrier layer andoverlapping in the area extending along the seam of the outer shellfabric.
 14. The product of claim 13, wherein the inner lining fabriccomprises a fleece material or a tricot material.
 15. The product ofclaim 13, wherein the inner lining fabric comprises multiple layersquilted together.
 16. The product of claim 13, wherein the inner liningfabric comprises a material selected from the group consisting ofpolyester, polyamide, polyvinylchloride, polyketone, polysulfone,polycarbonate, fluoropolymer, polyacrylate, polyurethane,co-polyetherester, polypropylene, and co-polyetheramide.
 17. The productof claim 1, wherein the adhesive is selected from the group consistingof powder adhesive, web adhesive, microdot adhesive, and nanodotadhesive.
 18. The product of claim 1, wherein the outer shell fabriccomprises a material selected from the group consisting of polyester,polyamide, polyvinylchloride, polyketone, polysulfone, polycarbonate,fluoropolymer, polyacrylate, polyurethanes, co-polyetherester,polypropylene, and co-polyetheramide.
 19. The product of claim 1,wherein the outer shell fabric comprises multiple layers quiltedtogether.
 20. The product of claim 1, wherein the product is an articleof clothing, a portion of an article of clothing, a jacket, a coat, aparka, a raincoat, a cloak, a poncho, a shirt, a blouse, pants, a shoe,a boot, a glove, a hat, a hood, underwear, an undershirt, briefs, a bra,socks, a diaper, a protective suit for handling of hazardous materials,a protective suit for a firefighter, military personnel, or medicalpersonnel, a blanket, a towel, a sheet, pet bedding, a tent, a sleepingbag, a tarp, a boat cover, carpeting, a rug, a mat, a window covering,or upholstery.
 21. A composite material comprising: a first layercomprising a high melt membrane film, the high melt membrane filmcomprising a material selected from the group consisting of polyester,polyether, polypropylene, polyurethane, thermoplastic polyurethane,PTFE, and expanded PTFE; a second layer disposed on a first side of thefirst layer, the second layer comprising a low melt membrane film, thelow melt membrane film comprising a material selected from the groupconsisting of polyester, polyether, polypropylene, and polyurethane;wherein the low melt membrane film has a melting temperature lower thana melting temperature of the high melt membrane film.
 22. The compositematerial of claim 21, further comprising: a third layer disposed on asecond side of the first layer, the third layer comprising a lower meltfilm, the lower melt film comprising a material selected from the groupconsisting of polyester, polyether, polypropylene, and polyurethane;wherein the lower melt membrane film has a melting temperature lowerthan the melting temperature of the low melt membrane film.